Western Products, PO Box 245038, Milwaukee, WI 53224-9538 www.westernplows.com August 1, 2010 Lit. No. 41537, Rev. 00 33220 MOUNT KIT Jeep Wrangler 2007 - Installation Instructions Read this document before installing the snowplow. See your WESTERN outlet/web site for specific vehicle application recommendations before installation. The Selection List has specific vehicle and snowplow requirements. A DIVISION OF DOUGLAS DYNAMICS, L.L.C.
SAFETY SAFETY DEFINITIONS Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTE: Indicates a situation or action that can lead to damage to your snowplow and vehicle or other property. Other useful information can also be described. / & INSTRUCTION LABELS Become familiar with and inform users about the warning/caution labels on the back of the blade and the instruction label on the headgear. NOTE: If labels are missing or cannot be read, see your sales outlet. Warning/Caution Label LOWER BLADE WHEN VEHICLE IS PARKED. DO NOT EXCEED GVWR OR GAWR INCLUDING BLADE AND BALLAST. REMOVE BLADE ASSEMBLY BEFORE PLACING VEHICLE ON HOIST. READ OWNER'S MANUAL BEFORE OPERATING OR SERVICING SNOWPLOW. TRANSPORT SPEED SHOULD NOT EXCEED 45 MPH. FURTHER REDUCE SPEED UNDER ADVERSE TRAVEL CONDITIONS. PLOWING SPEED SHOULD NOT EXCEED 10 MPH. SEE YOUR SALES OUTLET/WEB SITE FOR SPECIFIC VEHICLE APPLICATION RECOMMENDATIONS. 59900 Instruction Label Multiple Pinch Points Label WIDE-OUT Blades Only (both sides) Lit. No. 41537, Rev. 00 3 August 1, 2010
SAFETY SAFETY PRES Improper installation and operation could cause personal injury and/or equipment and property damage. Read and understand labels and the Owner's Manual before installing, operating or making adjustments. Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components. Failure to do this could result in serious personal injury. The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and the blade or within 8 feet of a moving blade. A moving or falling blade could cause personal injury. Keep hands and feet clear of the blade and A-frame when mounting or removing the snowplow. Moving or falling assemblies could cause personal injury. Do not exceed GVWR or GAWR including the blade and ballast. The rating label is found on the driver-side vehicle door cornerpost. To prevent accidental movement of the blade, always turn the control OFF whenever the snowplow is not in use. The power indicator light will turn OFF. Remove blade assembly before placing vehicle on hoist. Refer to the Selection List for minimum vehicle recommendations and ballast requirements. PERSONAL SAFETY Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. Wear only snug-fi tting clothing while working on your vehicle or snowplow. Do not wear jewelry or a necktie, and secure long hair. Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. Always have a fi re extinguisher rated BC handy, for fl ammable liquids and electrical fi res. FIRE AND EXPLOSION Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tanks and lines. Wipe up any spilled gasoline immediately. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or fl ame. CELL PHONES A driver's fi rst responsibility is the safe operation of the vehicle. The most important thing you can do to prevent a crash is to avoid distractions and pay attention to the road. Wait until it is safe to operate Mobile Communication Equipment such as cell phones or two-way radios. VENTILATION Vehicle exhaust contains lethal fumes. Breathing these fumes, even in low concentrations, can cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside. Lit. No. 41537, Rev. 00 4 August 1, 2010
SAFETY TORQUE CHART Read instructions before assembling. Fasteners should be finger tight until instructed to tighten according to the torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment. Recommended Fastener Torque Chart (ft-lb) Size SAE Grade 2 SAE Grade 5 SAE Grade 8 1/4-20 5/16-18 3/8-16 3/8-24 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 Size M 6 M 8 M 10 6 11 19 24 30 45 66 93 150 150 220 9 18 31 46 50 75 110 150 250 378 583 Metric Grade 8.8 (ft-lb) Torque 7 17 35 Size M 12 M 14 M 16 These torque values apply to fasteners except those noted in the instruction. 13 28 46 68 75 115 165 225 370 591 893 Torque 60 95 155 Lit. No. 41537, Rev. 00 5 August 1, 2010
MOUNT INSTALLATION INSTALLATION INSTRUCTIONS NOTE: For easier assembly and installation, vehicle and all snowplow components should be on a smooth, level, hard surface, such as concrete. 1. Remove the bumper and air dam. Retain fasteners for later reinstallation. 2. For 2007 2009 Models: Align the four front holes in the mount with the four holes in the underride protection beam brackets. NOTE: Front wheels should be straight ahead for easiest installation. 3. Insert two 1/2" x 1-1/4" cap screws with short (5-1/2") handles and two 1/2" washers into the truck frame out through the front mount holes on each side. Attach 1/2" locknuts and fi nger tighten. 4. Push the entire mount tight up against the vehicle frame so that the rear stiffeners contact the frame. Tighten the four front fasteners so that the mount is fi rmly held against the frame. Use caution not to pinch, cut or drill through any wires or hoses running along the frame rails. For 2010 and Later Models: Align the bottom hole in the mount with the top hole in underride protection beam brackets as shown below. Use the top hole in the mount as a template to drill a 17/32" hole through the bracket. Drill a 17/32" hole here. Align the bottom hole in the mount with the top hole in the bracket. Lit. No. 41537, Rev. 00 6 August 1, 2010
MOUNT INSTALLATION Use caution not to pinch, cut or drill through any wires or hoses running along the frame rails. 5. Using the holes in the rear of the mount as guides, drill a 17/32" hole through the frame rail on each side of the vehicle. Drill a 17/32" hole here. 6. Insert a 1/2" x 1-1/2" cap screw with long (18") handle and a 1/2" washer into the front of each frame rail and out through the drilled holes on either side. Attach a locknut and fi nger tighten. 7. Install the cross bar using four 1/2" x 1-1/2" cap screws and 1/2" locknuts. Hand tighten fasteners. 8. Tighten all fasteners according to the torque chart. Bend or cut handles protruding from the frame to improve appearance. 9. Modify the air dam as needed. Reinstall the air dam and bumper using original fasteners. NOTE: After five to ten hours of snowplow usage, retorque all mount assembly fasteners. Lit. No. 41537, Rev. 00 7 August 1, 2010
Western Products PO Box 245038 Milwaukee, WI 53224-9538 www.westernplows.com A DIVISION OF DOUGLAS DYNAMICS, L.L.C. Western Products reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifi cations used. Western Products or the vehicle manufacturer may require or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. Western Products offers a limited warranty for all snowplows and accessories. See separately printed page for this important information. The following are registered ( ) or unregistered ( ) trademarks of Douglas Dynamics, L.L.C.: UltraMount, WESTERN. Printed in U.S.A. Lit. No. 41537, Rev. 00 8 August 1, 2010